engine TOYOTA AVENSIS 1999 Supplement

PP11J–02
PP–10
– PREPARATIONSUSPENSION AND AXLE
LUBRICANT
ItemCapacityApplication
1CD–FTV engine:
Outboard joint grease Color=Black
Inboard joint grease Color=Yellow
85 – 105 g (3.00 – 3.70 oz.)
120 – 130 g (4.23 – 4.59 oz.)

PP27X–01
PP–12
– PREPARATIONSTEERING
STEERING
SST (Special Service Tools)
09640–10010Power Steering Pressure Gauge
SetPower steering fluid
(09641–01010)Gauge Assy
(09641–01030)Attachment B
(09641–01060)Attachment E
09950–60010Replacer SetPS vane pump
(2C–T, 2C–TE and 1CD–FTV
engines)
(09951–00310)Replacer 31
09950–70010Handle SetPS vane pump
(2C–T, 2C–TE and 1CD–FTV
engines)
(09951–07100)Handle 100
09960–10010Variable Pin Wrench SetPS vane pump
(2C–T, 2C–TE and 1CD–FTV
engines)
(09962–01000)Variable Pin Wrench Arm Assy
(09963–01000)Pin 10

PP27Z–01
PP–14
– PREPARATIONSTEERING
EQUIPMENT
Caliper gaugePS vane pump (2C–T, 2C–TE and 1CD–FTV engines)
Vernier calipersPS vane pump (2C–T, 2C–TE and 1CD–FTV engines)
Feeler gaugePS vane pump (2C–T, 2C–TE and 1CD–FTV engines)
MicrometerPS vane pump (2C–T, 2C–TE and 1CD–FTV engines)
Torque wrench

SS0G7–04
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
SS–7
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transaxle upper side x Engine Bolt A
Bolt B64
29650
29647
21
Transaxle lower side x Engine Bolt A
Bolt B
Bolt C
Bolt D
Bolt E40
40
8
20
46408
408
82
204
47030
30
71 in.·lbf
15
34
Diesel throttle body x Engine unit2121415
No.1 air tube assembly x Engine unit2525518
Diesel throttle body with No.2 air tube assembly x Engine unit2525518
Engine front mounting x Engine front mounting bracket8789064
Engine front mounting x Transaxle6465047
Engine rear mounting x Engine rear mounting bracket981,00072
Engine rear mounting x Transaxle6465047
Starter x Starter wire1515311
Starter x Transaxle3940029
Transaxle case protector x Transaxle2525018
Clutch release cylinder x Clutch housing121209
Clutch line bracket x Transaxle Bolt A
(See page MX–4) Bolt B12
4.9120
509
43 in.·lbf
Engine left mounting x Bracket8789064
Engine left mounting Bracket x Transaxle5253038
Front wheel1031,05076
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Center exhaust pipe4849035
Engine rear mounting x Center member7374054
Engine rear mounting bracket x Body6465047
Engine rear mounting bracket x Engine rear mounting8789064
Engine front mounting x Center member5254038
Engine front mounting bracket x Transaxle6465047
Engine front mounting bracket x Engine front mounting8789064
Front transport hook x Center member3940029
Engine mounting center member x Body7374054
Transaxle case protector x Transaxle2525018
No.2 selecting bellcrank with selecting bellcrank support2020014
Shift and select lever shaft lock bolt4950036
Shift and select lever shaft assembly x Transmission case2020014
Transmission case cover x Transmission case2930022
Breather plug4950036
Output shaft lock nut1231,25090
Shift fork and shift head set bolt2424017
Rear bearing retainer x Transmission case4243031
Straight screw plug2525018
Straight screw plug (Reverse restrict pin)131309
Reverse idler gear shaft lock bolt2930022

SS0IY–02
– SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS–9
SUSPENSION AND AXLE
SERVICE DATA
Front drive shaftDrive shaft standard length (1CD–FTV engine) RH
LH
2.0 mm (
0.079 in.)
548.15
 mm (21.58
0.079 in.)

SS0FT–04
SS–12
– SERVICE SPECIFICATIONSBRAKE
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Brake pedal x Brake pedal bracket36.837527
End cover x Casing7.88068 in.·lbf
Check valve x End cover7475054
Union x Check valve1414010
Vacuum pump x Engine2121415

SS0IF–02
– SERVICE SPECIFICATIONSSTEERING
SS–13
STEERING
SERVICE DATA
DRIVE BELT
4A–FE and 7A–FE engines:
Drive belt deflection New belt5 – 6 mm (0.20 – 0.24 in.)
Drive belt deflection Used belt6 – 8 mm (0.24 – 0.31 in.)
*Drive belt tension New belt441 – 539 N (45 –55 kgf)
*Drive belt tension Used belt245 – 392 N (25 – 40 kgf)
3S–FE engine:
Drive belt deflection New belt8 – 10 mm (0.31 – 0.39 in.)
Drive belt deflection Used belt10 – 13 mm (0.39 – 0.51 in.)
* Drive belt tension New belt441 – 539 N (45 – 55 kgf)
* Drive belt tension Used belt245 – 392 N (25 – 40 kgf)
2C–T, 2C–TE and 1CD–FTV engines:
Drive belt deflection New belt11 – 14 mm (0.43 – 0.55 in.)
Drive belt deflection Used belt15 – 18 mm (0.59 – 0.71 in.)
* Drive belt tension New belt539 – 637 N (55 – 65 kgf)
* Drive belt tension Used belt245 – 392 N (25 – 40 kgf)
POWER STEERING FLUID
Oil level rise Maximum5 mm (0.20 in.)
4A–FE and 7A–FE engines:
Oil pressure at idle speed with valve closed Minimum8,238 kPa (84 kgf/cm2, 1,195 psi)
3S–FE engine:
Oil pressure at idle speed with valve closed Minimum9,022 kPa (92 kgf/cm2, 1,309 psi)
2C–T, 2C–TE and 1CD–FTV engines:
Oil pressure at idle speed with valve closed Minimum8,826 kPa (90 kgf/cm2, 1,280 psi)
PS VANE PUMP (2C–T, 2C–TE and 1CD–FTV engines)
Pump rotating torque Maximum0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf)
Pump shaft and front housing bushing oil clearance STD
Maximum0.01 – 0.03 mm (0.0004 – 0.0012 in.)
0.07 mm (0.0028 in.)
Vane plate height Minimum8.1 mm (0.319 in.)
Vane plate thickness Minimum1.797 mm (0.0708 in.)
Vane plate length Minimum14.988 mm (0.5901 in.)
Vane plate and pump rotor groove clearance Maximum0.03 mm (0.0012 in.)
Vane plate length Pump rotor and cam ring mark
None14.996 – 14.998 mm (0.59039 – 0.59047 in.)
114.994 – 14.996 mm (0.59032 – 0.59039 in.)
214.992 – 14.994 mm (0.59024 – 0.59032 in.)
314.990 – 14.992 mm (0.59016 – 0.59024 in.)
414.988 – 14.990 mm (0.59008 – 0.59016 in.)
Flow control valve spring length Minimum36.0 mm (1.417 in.)
*: For use with belt tension gauge

SS0IG–02
SS–14
– SERVICE SPECIFICATIONSSTEERING
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
PS VANE PUMP (2C–T, 2C–TE and 1CD–FTV engines)
Pressure port union x Front housing6970051
Suction port union set bolt131309
Pulley cover x PS vane pump assembly3940029
PS vane pump assembly set bolt3940029
Union bolt x Pressure feed tube5252538
PS vane pump pulley set nut4344032
Idler pulley set nut3839028

MX096–02
D06619
Starter
39 (400, 29)
Clutch Release
Cylinder
and Line
12 (120, 9)
4.9 (50, 43 in.·lbf)
12 (120, 9)
Control CableClip
Clip
Washer Air Flow Meter
ConnectorAir Cleaner Case
Assembly
with Air Hose
52 (530, 38)
87 (890, 64)
Engine Left
Mounting Bracket
Battery
Tray
No.1 Air Tube Assembly
Diesel Throttle Body
with No.2 Air Tube Assembly
Stay
VSV Connector for EGR
Turbo Pressure
Sensor Connector
Intake Air Temperature
Sensor Connector
Throttle Full
Switch Connector
Throttle Control
Motor Connector

Gasket

Non–reusable part
21 (214, 15)
N·m (kgf·cm, ft·lbf): Specified torque
15 (153, 11)
25 (255, 18)
25 (255, 18)
25 (255, 18)
25 (255, 18)
MX–2
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MANUAL TRANSAXLE UNIT
COMPONENTS

D06618
RH Drive Shaft
LH Drive
Shaft
216 (2,200, 159)
Lock Nut Cap

Cotter Pin
Snap Ring
Front Exhaust Pipe
Engine Mounting
Center Member
LH Engine Under Cover RH Engine Under Cover
64 (650, 47)
Transaxle Case
Protector
25 (250, 18)
Back–Up Light
Switch Connector
Speed Sensor
Connector
Front Transport
HookHole Plug
Hole PlugHole Cover
64 (650, 47)
39 (400, 29)
73 (740, 54)
73 (740, 54)
52 (540, 38)
Tie Rod End
Engine Rear
Mounting Bracket
64 (650, 47)
98 (1,000, 72)
29 (300, 22)
64 (650, 47)
49 (500, 36)
127 (1,300, 94)
Ground Cable
Engine Front
Mounting Bracket
Engine Front
Mounting
Suction Pipe
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
Gasket
Gasket
8.0 (82, 71in.·lbf)
40 (408, 30)
x 10Bolt with Spring
20 (204, 15)
46 (470, 34)
62 (630, 46)
48 (490, 35)
40 (408, 30)
87 (890, 64)
64 (650, 47)
x 10
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE UNIT
MX–3